Mold flow analysis employs CAE software (such as Moldflow, Moldex3D) to simulate the flow, packing, cooling, and warping processes of plastic melts within the mold cavity. Mold flow analysis is conducted for double-wing molds at every design stage to identify risks such as trapped gas, weld lines, and sink marks in advance, optimize the process window, and reduce the number of mold trials from 7-8 to 2-3.
| ability | explanation |
|---|---|
| filling analysis | Predict the temperature at the flow front, shear heat, and stagnant flow region |
| Pressure holding analysis | Optimize the volume shrinkage rate by adjusting the holding pressure and time |
| cooling analysis | Cooling time prediction, whether the temperature difference is uniform |
| Warpage Analysis | Predict the amount and direction of part deformation, and guide the anti-deformation design |
| multi-cavity balance | Ensure consistent filling of all cavities (with a deviation of <2%) |
Instrument panel frame, door panel thin-walled parts, optimize filling balance and warpage
Reduce sink marks and flow marks on air conditioning panels and washing machine tubs
The precision connector features multi-cavity balance to avoid short shots
Analysis of flow channels in microfluidic chips
customer：A supplier of automotive exterior parts
product：Automotive decorative exterior parts (length 1.8m, wall thickness 2.5mm, material PP+EPDM)
challenge：Despite six attempts at mold testing, there are still weld lines and trapped gas
two-wing plan：Optimize the gate position through mold flow analysis and add exhaust slots
result：The second trial mold passed, reducing the development cycle by 4 weeks and saving 120,000 yuan in mold modification costs.
Thermal diffusion welding technology, commonly referred to as diffusion welding, is a precise solid-state joining technique. Its core principle involves bonding the surfaces of two precisely machined weldments in a vacuum or protective atmosphere. Under the combined effects of high temperature and pressure, microscopic plastic deformation and atomic-level interdiffusion occur on the contact surfaces, ultimately forming a metallurgical bond, thereby joining the materials together. Double-wing molds apply this technology to the manufacture of conformal cooling water channels, complex mold inserts, and micro precision molds.
| parameter | indicator |
|---|---|
| welding materials | Same/different metals (stainless steel-stainless steel), (aluminum alloy-copper) |
| temperature range | 200~1200℃ (depending on different materials) |
| pressure range | 5～50MPa |
| degree of vacuum | 10⁻⁴ Pa |
| Sealing Leakage Rate | ≤1×10⁻⁶ mbar·L/s |
| Maximum workpiece size | 1300*1300*400mm |
| welded products | Multi-layer or double-layer |
Machining and welding of conformal cooling water channels
Complex mold inserts and micro precision molds
Sealing of electrodes on microfluidic chips
Semiconductor packaging shell, vacuum brazing replacement part
customer：A manufacturer of industrial robots
product：A strange-shaped part of a lawn mower
challenge：Deformation due to abnormal heating, resulting in precision out of tolerance
two-wing plan：Diffusion welding technology facilitates conformal water flow, ensuring uniform heating of the product
result：The product is heated evenly, ensuring no deformation after injection molding and high precision
Micro-sensor housing (pressure/temperature), fuel injector sealing ring, connector terminal insulator
Mobile phone camera stand, smartwatch button, micro switch toggle handle
Microfluidic chips, hearing aid components
customer：A medical diagnostic company
product：Disposable microfluidic chip (channel width 80μm)
challenge：Bonding failure due to underfill, obvious weld lines, and warpage
two-wing plan：Utilizing a micro-injection molding dedicated mold cavity with vacuum extraction + localized mold temperature heating
result：The yield rate increased from 45% to 92%, with a CPK of 1.33 and a mass production cycle of 6 weeks
Multi-material injection molding involves injecting two or more different materials sequentially or simultaneously on the same injection molding machine to form inseparable composite products. The dual-wing mold, equipped with a rotary two-color injection molding machine and mold core rotation technology, can produce products such as hard plastic + soft plastic, dual-color marking, and metal-encased inserts. This eliminates the need for bonding or snap-fit assembly processes, enhancing reliability.
| parameter | indicator |
|---|---|
| Workstation | 2K / 3K（Dual/Tri-color） |
| Injection unit | Two independent sets（35t～160t） |
| Material combination | ABS+TPE, PC+TPU, PA+silicone, POM+TPE, etc. |
| Coating thickness | 0.5mm～5mm |
| Positioning accuracy | ±0.02mm |
Two-tone dashboard trim strip, door armrest rubber cover, rotary gear lever (hard + soft)
Electric tool handle, vacuum cleaner roller brush, washing machine button (dual-color identification)
Waterproof connector sealing ring coating, gamepad grip
Surgical forceps handle, electronic blood pressure monitor upper and lower covers (two-color sealed structure)
Client：A household appliance brand (electric toothbrush)
Product：Toothbrush handle (hard ABS + soft TPE anti-slip pattern)
Challenge：Layering occurs at the junction of two colors
Dual-wing solution：Adjust the injection delay and mold temperature of the two materials
Result：The bonding strength has passed the UL test, with a mass production yield of 98%
Two Wing Mold is a premier one-stop manufacturer of plastic injection molds and related services, based in ShenZhen, China. With a core leadership team that brings over 20 years of extensive industry experience, we combine deep technical expertise with proven craftsmanship to deliver superior molding solutions.
